TufFlight Manta User manual

Page1
5376AmalfiDrive, Clay, NY 13041 www.tufflight.com
Items Included in kit:
Foam Parts:
(1) “right” EPP wing core
(1) “left” EPP wing core
(1) 5/16” x 11” x 16” EPP tail fin sheet
(1) EPP fuselage/ wing center
Motor / Speed Controller:
(1)HimaxEPF50BLRTRfanunit
(1)15AESCw/connectors
Hardware:
(2) Dubro mini EZ connectors
(1) 0.039” x 8” wire
(2) Velcro fastener strips
white packing tape
(stuck to motor/ESC package)
Misc: (1) carbon spar tube
(1) 0.015” plastic parts sheet (thin)
(1) 0.038” plastic parts sheet (thick)
This Instruction Manual
Rev1.2
Hello, and thanks for buying the Manta-- an exciting park jet offering the perfect combination of convenience,
easy flying, durability, and thrills for the beginning to intermediate R/C flyer.
Caution: The Manta is a fast and agile flyer, and requires care in setup and operation. Please obey safety
rules for your motor and battery. Lithium polymer (lipo) batteries are ideal for this plane.
Charge lipo batteries ONLY with a lithium capable charger according to battery instructions.
The CG location is 3/4” ahead of the spar with the battery installed.
Please read and understand the instructions before starting to build. We recommend joining the AMA and
following the AMA safety code. Call 1 (800) I- FLY-AMA for more details.
We assume no responsibility for how you use your plane. That said, let's get started!
Wingspan: 34"
FlyingWeight: 9-10 oz
FanThrust: 10.2 oz
Motor/Fan: Himax EPF50BL RTR
brushless outrunner fan unit
ESC: included
Radio: 3+channels,elevoncapability
Servos: 2 Hitec HS 55 or equivalent
TheToughestR/C PlanesEver!

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Items needed to complete:
Equipment:
3cell(3S)800 - 1500 mAH Lithium polymer
batterycapableof13Acontinuousdraw
2servos:HitecHS 55 or equivalent
Transmitter(TX)capableofelevonmixing
3+channel microreceiver(RX)
batteryconnector
Adhesives:
QuickGrip(availableat
Walmartincraftsection)
Maskingtape
3/4”rolloffiberglass
reinforcedpacking tape
HelpfulTools:
40gritsandpaperon block
(availableatauto
finishingstoresandSears)
hobbyknife/utilityknife
scrapof sheet rock as a “cuttingboard”
solderingiron,solder
shrinktubeinsulation
soldering“jig”(ie,extrapairofhands)
heatgun
“hemostattype”pliers
Phillipsheadscrewdriver
straightscrewdriver
standardpliers
smallclamp
wirecutters
DremelToolw/drum sander
felttippen
ruler/straightedge
maskingtape
scissors
flatbuildingtable,atleast3 ftlong
yourchoiceoflightweightfinish:
magicmarkers, orlightweightpaint
airbrush(recommended)
NotesonLithiumPolymer (LiPo)
Battery Use:
Firstly,chargeLiposusingONLYlithiumcom-
patiblechargersaccordingto themanufacturer’sspecs.
Secondly: Do NOT drain the batteries to the
pointwheretheplanewillnolongerfly. Lithiumbat-
teriesWILLbedamagedifthey are drained too much.
Notes on Conventions:
Referencesto“Left”, “Right”, “Front”and“Rear”
areassumedtobefroma“pilot’s”pointofviewasthough
(s)heweresittinginthecockpit. Pleasekeepthisinmind
when viewing pictures in the construction steps. The
“LeadingEdge” ofapartis the“front”edge, andisoften
abbreviatedas“LE”. The “TrailingEdge”isthe“rear”
edgeandusuallyabbreviated“TE”. The“Fuselage”is
the“body”oftheplaneandisoftencalled“Fuse”(rhymes
with“loose”)forshorthand. Thesearecommontermsin
R/Cmodeling. “Top” or“Bottom”areas youwouldex-
pect, with the plane sitting or flying upright. A“root”
edgeofsomethingis nearthefuselageandis usuallybig-
gerthanthe“tip”whichisfurthestaway. Thetotallength
ofawingisthe“span.”Awingusuallyhasa“spar”atthe
thickestpart runningtheentire spanofthe wing.
Notes on Servo setup, control sensitivity
and finishing (paint):
We supply Hitec HS 55 servos in our deluxe kits,
andtheseinstructionsshowtheirinstallationanduse. The
suppliedcontrolhorndimensionsassumethebuilderwill
usethe outermost holesin theHitec servo arms togive
excitingaerobaticroll--about 45 degrees of deflection.
Thisis how weset upour personal planes andwhat we
usefortheaerobaticsfeaturedin our videos.
If you desire a more docile plane, move the ez
connectorone hole closer totheservo screw. Do NOT
limitthethrowusingtheradio! It’salways besttodothis
mechanically.
Foreasiercontrol, you may need to programyour
elevonsso ELEVATORpercentagetravelis less than
AILERONpercentage. (Itis common for thedefault
elevontransmitter programstogive a50/50mix
contributionforaileron+elevatorinput).
Foraerobaticflyingwingsitisusuallydesiredtohave
muchlesselevatortravelthanaileron. Elevatortravel may
beaslowas30to40%dependingon yourplane’sweight
andCG. The lighter the plane, the tighterit willturn. If
youhavetoomuchelevatorthrow,yourplanecould“snap
roll”outofaturnour loop if it’sheavy. YourMantahas
greatturningtraits,andwilllikely notexhibitthisissueif
builtaccordingtoour directionsandnotmadetoo heavy.
Keep your paint job light! Beware of spray
paintin cansbecause it’s easyto makeyourplanetoo
heavywhenthepaint soaksintothefoam. Useonly light
mistinginkeyareasandavoidcoloringtheentireplane if
usingspraypaint in cans. Anairbrushgives superior
lightweightpaintcoverageover cans orbrushing.

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Step5:Bendandsnapthepartfreebyflexing
theplastic on thescoredoutline.
Step4:Scoretheplasticwithahobbyknife
ontheoutlineof the battery cover as shown.
Step3:Tape the thin plastic sheetover the
batterycovertemplateas shown
Step2: Remove centerfold templatesheetsfrom
thismanual
Step9:Now score the horn outlines with a
hobbyknifelike you did theotherpieces.
Step8: Drill the twoholeswithyourhome-
made0.039” drillbit
Step6:Tape thick plastic sheetover
controlhorntemplate and mark holeloca-
tions
Step 1: Gather parts and tools
Cut out pieces using paper templates
You’ll need : centerfold template pages
0.039” wire, drill, prick punch
hobby knife, masking tape
both plastic sheet pieces (thick, thin)
EPP foam sheet, wire cutters, metal file
long nose pliers
The paper shows
through the plastic
you don’t need to
cut all the way
through, just
press hard
enough to leave a
groove
use a prick punch to
make dimples where
holes will be drilled
in the next step
careful not to drill
into your table!
(use a scrap piece of
wood underneath)
Step7:Make a “drill bit”from 0.039” wire.
Fileapointon one end and cut to 3/4” long
Step10:Snap out the control horns.Use
plierstogetabettergriponthethickplastic
mark parts with
masking tape or
erasable marker if
you think you might
lose them
Cut the sub fin
cover plate also
Set these aside for
later

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Step14:Apply the fan ring to the front as
shown
Step13:Remove theplasticflangearound
themotor withpliersasshown
Step 12:Gather parts and tools
Step 11:Tapepaper template to foam sheet
andcut out finwithasharp hobby knife.
Step15:Gluetheringtothefan with Quick
Gripas shown
Separate the foam sheet
from between the wing
parts if necessary
A piece of scrap drywall
makes a good cutting
board underneath.
Configure motor and radio electronics
You’ll need : Quick Grip, tweezers
hobby knife, masking tape, screwdriver
pliers, solder, soldering iron, heat gun
solder jig, shrink tube, wire cutters
fan unit, ESC, servos, RX, TX, servos
battery connector, battery
You can either “peel” it
away as shown, or
break it off in small
pieces.
Don’t worry about
being to neat here
Step 17:Cutthe battery connector as
shown.Strip 3/16”insulationoff wireends.
Step16:Usethefullsizetemplateon page 12
tocutthe ESC battery leads where shown
Step20:Solder the wires
Step19:Slip heatshrink tubes over the
batteryconnector
Step 18: Cut five sections of heat shrink
tubingabout 3/8”longeach
take your
time and do
a good job
Blow torches
need not
apply!
Depending on your
selected battery size,
you may have a
different connector.
“JST” is shown

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Step30:Carefullypeelawayspiderwebs.
Step29: Removethecenterfoamcylinder
andsaveitfor later
Step28:Separate the foamfuselage pieces
asshown
Step 27:Gather parts and tools
Step21:Slide the heat shrink tubingtocover
thesolder jointandshrinkwith a heatgun
Prepare Wing and Fuselage Foam parts
You’ll need : Quick Grip
hobby knife, masking tape, CA kicker
40 grit sandpaper on block
Peel away
spider webs
from inside
surfaces too
if you can
reach them.
Step 23:AdjustESClowvoltagecutoffif
neededso fanspinsreliably.
Step24:Centeryour radio trims, and
activateyourelevonmixingfeature.
Step22:Hookup all your radio partsthen
testfan operation andthrustdirection.
Step 25:Clipoffoneend of the servoarms as
shown
Carefully test
your motor, then
return your
throttle stick to
the OFF position
Consult ESC directions and adjust small switches
so your fan spins smoothly from low to high
throttle.
We find the 11.1 V setting sometimes is not
reliable, so select a lower setting to get good
operation.
Step26:Installservo arms so they are90
degreesas shown withtrimscentered

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Step32:Repeat for all wing surfaces.
Step31:Usecylinderto“sand”wing
surfacestohelpremovespiderwebs.
Step34:Trim 1/8” from the elevonrearTEas
shownanddiscard.
Step33:Placeametalstraightedgealongthe
wingTEtoexpose 1/8” of the elevon edge
place the wing on
a flat cutting
surface
A scrap piece of
drywall makes a
good cutting board
a sharp hobby knife
works best.
Watch your fingers!
This makes a nice
clean straight TE
Step 35:Apply a bead ofQuickGrip to the
hingelineasshown
Step36:Smeartheglue with yourfingerinto
thehingelineasshown.
Step38:Flex the elevonsandLIGHTLY
sandthehingelineasshown
this step makes
the hinge more
free
Sand the
BOTTOMS
ONLY
(opposite of
glued sides)
Step37:Bendtheelevon down slightlyand
tapeinplacewhilegluedries.
Repeat for
other
wing top
hinge
surface
Quickly
proceed
to the
next step
Step40:Cuttheleft wing templatealongthe
rootedge line whereshown
Step 39:Gather parts and tools
Make Wing cavities for component installation
You’ll need : centerfold template sheet,
hobby knife, masking tape,
radio components
pencil, scissors, pliers,
Dremel tool w/ small drum sander

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Step44:Slicetheoutlineforthe receiver
cavity. Useyourreceiverforadepthgauge.
Step43: Sliceintotheservooutlinewhere
showntothedepth of the servo
Step42:Slice throughthetemplatecontrol
hornlocationwhereshown
Step45:Trace in allthesliceswithapencilso
youdon’tlosetrackofthem.
Step41:Align thetemplateover theleftwing
bottom sothe spar androot edgesmatch
tape template onto wing
bottom (with the spar slot)
using masking tape
put the wing on a
cutting board for this
step
(slice all the way
through the foam
holding a sharp hobby
knife vertically)
Don’t slice all the way
through the foam!
Use your servo for a
depth gauge and make
the slice the same depth
Make the slice
slightly deeper than
your receiver
(about 1/8 to 1/4”
deeper)
Make the pencil marks
dark enough so you can
see the outlines when you
remove the template
Step 50:Gather parts andtools
Step49:Applytherightwing templateand
performthesestepssimilarlyforthiswing.
Step48:Make servo cavitysimilarly. Testfit
sothe servoslieflush withwingbottom also.
Step47:TheDremeltoolmethodissuperior
formakingcleanandprecisecavities
Step 46: Remove foam from thereceiver
cavityarea. CAREFULLYpulloutwithpliers
If you have a Dremel
tool with a small drum
sander skip to next step
IF you accidentally
pull out foam through
to the top surface, just
glue it back in place
Install Fan and Servos
You’ll need : assembled fan and ESC
foam fuselage and wings
Quick Grip,
hobby knife
firmly hold the drum
sander to the right depth
and slowly proceed
NEAR the edges. When
you get close to the edge,
the foam will “snap”
clean by virtue of the
knife slits

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Step58:Slice a shallow groove to routethe
wiresfromthe servo totheRXcavity.
Step53:Applyalineofglue around the
bodyofthe fan unitasshown
Step52:Applyglueto the center seam as
shown
Step51:Route the motor wires in a line
directlybehindone of the statorsasshown
Step55:Squeeze the fuselage together as
shown
Step54:Insertfaninto fuselagewithwires
pointingasshown
Step57:Glue servosintowingcavities as
shown
Step56:Tapethe fuselage to clamp it while the
gluedries asshown
Step 60:deburr both ends of the carbon spar
withasandingblock
Step 59:Gather parts and tools
Assemble wing to fuselage
You’ll need : foam fuselage, foam wings,
carbon spar, masking tape,
sandpaper on block,
Quick Grip
Do for
other
wing also
Just do
the left
wing for
now
(with the
RX
cavity)

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Page17
Step65:Separateand apply Quick Grip into
thejoint asshown
Step63:Align thewingsurfacesevenwith
thefuselageasshown
Step64:Examinethe spar ends and sand
themflushiftheyprotrudeslightly
Step62:Centerthe spar as shown in thisand
followingsteps
Step61:Insert the spar into the fuselage
holewhereshown
don’t glue
the spar
yet
Repeat for
both wing/
fuse joints
Step66:Be sure the surfaces are flushas
shown
Step 67:Usemaskingtapetotightlyholdthe
jointtogether
Step68:Carefully slide out the spar and apply
glueinto thegrooveasshown.
Step 69:Applygluetootherwingalso
Step 70:Reinsertthespartwirlingitasyougo
tohelpevenlydistributetheglue
Wipe away
any glue
which
squirts out
of the spar
joint

Page18
Step 75:TapeESC to fuse whereshown
whilegluedries.
Step73:Usinga Dremel tool, create a
cavitysotheconnectorswill“lieflat.”
Step74:Applyglue to the ESC
Step72:Correctlyconnect wires and bend
back.Trace around connectors as shown.
Step 71:Gather parts and tools Step76:With asharpknife,carefully route the
rightwingservowire asshown.
Step 77:Also slice a path fromtheESCto the
receiverfor thethrottleconnectionas shown.
Step78:Apply Quick Grip tothe Battery
connectorandclamp tofusewhere shown.
Step79:Completed fuselage bottom.
Install ESC components
You’ll need : assembled wing and fuselage
ESC assembly, small plastic clamp
Quick Grip, hobby knife, battery,
Dremel Tool with drum sander
hemostat pliers, masking tape,
transmitter, marker
Step 80:Gather parts andtools
Configure Controls and Install Receiver
You’ll need : assembled wing and fuselage
Quick Grip, push rod template, pliers
control horns, ez connectors, sandpaper,
push rod wire, screwdrivers,wire cutters
radio receiver, transmitter, battery,
hobby knife, white packing tape
test motor
direction
(Consult
Step 22)
cut a smooth
path from the
servo to the
receiver
cavity just
deep enough
to hide the
wire
Note
connector
faces
forward

Page19
Step88:Makepushrods with Z bends using
fullsize templateonpage12 as shown
Step 87:Deburrendsof the 0.039” wire
withsandpaper
Step85:Installscrewintoconnectorasshown Step90:InsertZbend into control horn as
shown
Step 89:Cutpush rod to lengthand repeat
forother
Step84:Installthemini ezconnectorsinto
theservoarmsasshown
Use the outermost
holes in the servo
arm now.
If you want more
docile controls, you
choose an inner hole
later on.
Step86:Make clearance inthe foamas
neededfor fullservotravel
Turn on your
radio and
operate servo
for the full
range to test
*Note, these picture shows our
Stingray which is a bottom wing
plane with servo arms
protruding through top surface.
Your Manta servo installation
will look slightly different, but
this process is the same.
Step 81:Testfittheplastic control horn into
theelevonslot. Enlargeslotasneeded.
Step83:Apply Quick Grip to the control horn
andglueinplace.
Step82:Place it so the hole iseven with the
hingelinewhenthewingisflatonthetable
Control horn
bottom edge
should be flush
with elevon top
surface
also see next step
for proper location
(this IS critical for
a good flying
plane, so take your
timehere)
Bottom
Surface

Page20
Step93:Turn on radio and center trims.
Tightenscrewwhenelevonis“flat”
Step91:Insert other end into ez connector
asshown
Step92:Makeallreceiverconnectionsifnot
alreadydone.
Step94:Test your radioelevon program to
ensureservosmovecorrectly. Reprogramor
switchwiresifneeded.
Up elevator (down
stick) makes both
servo arms push the
elevons up
Right aileron
(right stick) makes
right servo push,
and left servo pull
Step95:Make a shallow slit to hidethe RX
antennaon thewingbottom surface
Make a long continuous slice just
long enough for the length of your
RX antenna wire in the wing bottom
(opposite RX and ESC)
Try to route it away from the spar
and all other wires, and keep about
2” forward of the elevon hinge line
at the control horn location
Step96:InstalltheRX antennawireintothe slit
withaphillipsheadscrewdriver
Note a long 72
MHz receiver
antenna wire is
shown
If using 2.4 GHz,
your slits may be
very short and near
the receiver cavity
Step 97:TuckwiresneatlyintoRXcavity and
applyQuickGriptotheperimeter as shown
Step 100:Trim excess tape with knife.
Step98:Remove the white packing tape from
themotor/ESCpackage
Step99:Apply tape overreceiver cavityas
shown.
Smear it over the foam
so it coats it over a 2”
wide section and
longer than the cavity
This helps the tape
stick in the next steps